Custom-made footwear

ABSTRACT

A custom-made shoe of a sandal-type having a sole, an orthotic unit prescribed specially for the foot of the wearer adhered to the sole a vamp unit secured forwardly to the sole, and a counter secured to and projecting upwardly from the rear periphery of the sole.

TECHNICAL FIELD

The present invention relates generally to footwear and specifically tocustom made footwear incorporating orthotics.

BACKGROUND ART

The foot is a highly complex structure, containing 26 bones, 29 joints,and 42 muscles. Some statistics show that in a lifetime, the averageindividual will walk some 115,000 miles, or more than four times aroundthe world. It is not surprising therefore, that good footwear is one ofthe most important items of apparel; and when added to millions ofpeople who suffer from orthopedic problems of the foot and spine, thatcustom footwear is a major means of providing comfort for these andother people.

The use of custom made orthotics--inserts for shoes; orthopedic shoesfor helping certain foot problems; shoe modifications in the form ofheel build-ups; and rocker-type bottoms for shoes, as examples ofsolving certain orthopedic problems are well known in this field.

Historically, however, men and women who normally use prescriptionorthotic devices in their shoes are forced to temporarily give up thecorrective or stabilizing orthotics if they want to wear sandals due tothe nature and design of the sandals. Ordinary sandals lack the abilityto stabilize the heel of a patient's foot because there is typicallyonly a narrow strap that wraps around the ankle. Additionally, if apatient tried to use an orthotic insert with a sandal, the insert wouldnot remain in place because of the sandal's loose fit and open toe, heeland sides. It is to the provision of a solution to this problem thatthis invention is directed.

DISCLOSURE OF THE INVENTION

The present invention comprises a custom-made sandal that incorporatesorthotic elements and heel stabilizers to provide postural support andstability to its wearer.

The custom made orthotic portion of the sandal supports the three archesin the foot; the inner-longitudinal arch (navicular), theouter-longitudinal arch (cuboid), and the anterior transverse arch.Rear-foot posting for pronation or supination is also built into theorthotic design to achieve proper foot posture and balance. Heel spuraccommodations as well as a heel lift for an anatomical short leg can bebuilt into the orthotic based on the individual's needs.

The sole, or bottom of the sandal is shaped and sized to fit the foot ofthe wearer and is made of a thermoplastic rubber material for durabilityand shock absorption. An intermediate layer of a stiff fiber material issimilarly shaped and adhered to the top of the sole. Water resistantsponge rubber supports for the three arches in the foot are formed,located and adhered to the top of the intermediate layer to satisfy theprescribed support needs of the wearer. An open cell polyurethane foamheel pad is also adhered to the top of the intermediate layer for shockprotection during the heel strike phase of the gait cycle. A top layerof slip-resistant, black-knobby rubber is then applied over the foot bedto provide a non-slip, foot cushioning surface. The top layer provideswater-tight protection to the sandal interior.

Attached to the sole and extending around the heel portion of the sandalapproximately one-third its length is a rear-foot support element tocontrol pronation or supination thereby maintaining proper foot postureand balance. The rear-foot support comprises a rigid plastic elementthat may be covered by neoprene padding and a nylon liner or othersuitable material for comfort and durability. Also attached to the soleis a fore-foot strap located on the sandal where the wearer's metatarsaljoints will be received. The strap can be made of leather or othersuitable material for durability, looks and long wear. The straputilizes a hook and loop adjustable strapping system for adjustable fitand support. A rear-foot strap is attached to the rear-foot supportelement, and crosses over the front of the wearer's ankle and utilizes ahook and loop adjustable strapping system for adjustable fit andsupport. The rear foot strap is made of the same material as thefore-foot strap.

It is an object of this invention to provide a novel footwear that willallow patients/wearers to have orthotic support for all theiractivities.

It is another object of this invention to provide a novel sandal thatwill provide postural support, stability and shock absorbingcapabilities.

Yet another object of this invention is to provide a custom-made shoe orsandal that provides an exact prescription orthotic support forindividuals.

Still another object of this invention is to build custom-made spinalpelvic stabilizers right into attractive, comfortable sandals.

Another object of this invention is to provide to those individuals whorequire postural support, an enjoyment heretofore missed, that ofwearing sandals.

It is another object of this invention to provide a sandal that has anon-slip, foot cushioning surface formed over the orthotic elements,which surface is also water-tight so the sandal can be worn in wetconditions without damaging the orthotic elements.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other attributes of the invention will become more clear uponmaking a thorough review and study of the following description of apreferred embodiment, particularly when reviewed in conjunction with thedrawings, wherein:

FIG. 1 is a top plan view of a sandal embodying this invention;

FIG. 2 is a side elevational view of the sandal of FIG. 2;

FIG. 3 is a sectional view as taken along the line 3--3 in FIG. 1;

FIG. 4 is a bottom plan view of the shoe of this invention with the soleremoved; and

FIG. 5 is an exploded, perspective view of certain parts of thisinvention.

BEST MODE FOR CARRYING OUT THE INVENTION

Referring now to FIG. 1, the embodiment of the invention depictedincludes a shoe (10) of the sandal type provided generally with a sole(11), an orthotic unit (12) adhered to the sole (11) and tailored to aparticular individual's foot, and including further a shock absorbingheel inset (13), a vamp unit (14) for partially covering a foot (notshown), and a counter (16) projecting upwardly from the rear peripheryof the sole (11).

More particularly, the sole (11) comprises a sole proper (17) of anoutline to support the entire foot; of a thickness as predetermined forthe use, in this instance with a base (18) of a criss-cross, deeply cutstructure of a thermoplastic rubber material (FIG. 3). An upturned lip(19) is formed about the periphery of the sole proper (17), with ahigher raised portion (21) (FIG. 5) at the heel area, and an even higherportion (22) for additional support at the instep. The upper face (23)(FIG. 5) of the sole proper (17) has a pair of forward, transverselyopposite recesses (24), (24'), a second pair of intermediate,transversely opposite recesses (26), (26') and a U-shaped recess (27) atthe rear thereof, all formed in the face (23) for securement withportions of the vamp unit (14) and the counter (16).

The orthotic unit (12) comprises a lower, semi-flexible element (28) andan upper, semi-flexible element (29), both elements (28), (29) having anoutline similar to that of the sole proper (17) such as to fit withinthe lip (19). The elements (28), (29) are of a fiberboard-type material,and can be combined into a single element if desired. Sponge rubber archsupport elements (31), (32), (33), (34) (FIG. 5), formed according toprescribed arch support needs of the individual for whom the shoe (10)is custom-made, are adhered to the upper surface (30) (FIG. 3) of theupper element (29) at prescribed locations.

The heel inset (13), made of a polyurethane foam providing a higherdegree of shock absorption than the arch support elements (31)-(34), andof a curved shape to fit over the rear portion of the upper element(29), is adhered to the upper element (29) such that the rear, curvedperipheries of each mate. It will be noted (FIG. 3) that the heel inset(13) has a thickness similar to the combined thickness of the twoelements (28), (29) and is not covered over or placed beneath any of thearch support elements (31)-(34). The elements (31)-(34) and the heelinset (13), along with remaining exposed areas of the upper elementsurface (30) are covered over by a layer (36) of slip-resistant, knobbyrubber material; the layer (36) having an outline similar to that of theupper element (29) and a thickness similar to that of the heel inset(13).

Preparation of the orthotic unit (12) may comprise use by achiropractor, or other health care professional person skilled in thisfield and licensed to prescribe orthotics, of a casting kit as describedin U.S. Pat. No. 3,320,347 entitled Method of Making an Arch Support byMeasuring an Impression of a Foot, issued May 16, 1967 to M. H.Greenawalt, which patent is incorporated herein by reference.Preparation of the orthotic unit (12) may also comprise the use of anelectronic casting machine that is capable of sending three dimensionaldata of the foot to the laboratory for manufacturing purposes. Theresults of the casting or foot impression mold are then analyzed and aprescription is generated. Other methods of preparation may be utilized,and the invention is not to be limited thereby. These elements (31)-(34)support the three arches of the foot: the inner-longitudinal arch(navicular), the outer-longitudinal arch (cuboid), and the anteriortransverse arch. The heel inset (13) is placed into the heel zone of theorthotic unit (12) to absorb shock during the first phase (heel strike)of the gait cycle. Rear foot posting for pronation or supination isbuilt into the orthotic design to achieve proper foot posture andbalance. Heel spur accommodations as well as a heel lift for ananatomical short leg can be built into the orthotic based on theindividual's specific needs.

The vamp unit (14) (FIGS. 1-4) comprises separate forward and rear vampportions (37), (38). The forward portion (37) is primarily of a naturalsuede leather and includes a left V-shaped strap (39) having free ends(41), (42) (FIG. 4), and a right V-shaped strap (43) also having freeends (44), (46) (FIG. 4) and a free securing end (47) (FIG. 1). On itsinner surface, the end (47) is provided with an elongated Velcro loopportion (48); and on the outer surface of the right strap leg (50) (FIG.3), an elongated Velcro hook portion (49) is provided such that uponpassing the securing end (47) through a buckle (51) affixed to the leftstrap (39), the securing end (47) may be adjustably, secured to theright strap leg (50) to properly fit over the foot of the wearer. Thefree ends (41), (42) of the left strap (39) are affixed, as by glueingor the like around the edges of the elements (28), (29) and beneath sameas shown in FIG. 4.

The rear vamp portion (38) is also of a natural suede leather andcomprises a loop (52) affixed to the counter (16), with a buckle (53)(FIG. 2) held thereby, and a strap (54) one end (55) (FIG. 3) secured tothe counter (16) on a side opposite the loop (52), and the other end(56) free. Elongated portions (57), (58) of Velcro hooks and loops,respectively, are sewn end-to-end along the inner side of the strap (54)such that it may be passed through the buckle (53) and then adjustablyfolded and held against itself due to the Velcro portions (57), (58),positioning the rear vamp portion (38) comfortably over the instep ofthe wearer's foot.

Lastly, the counter (16) of the custom-made shoe (10), herein of thesandal-type, comprises a rigid, cup-shaped heel support (59) formed ofplastic or other suitable material, and having a lower, U-shaped ledge(61). A cup-shaped padding element (62) (FIG. 3) of neoprene is adheredto the inner surface of the support (59), a liner (63) of a softmaterial is formed completely about the interior of the element (62) andthe remainder of the heel support (59), and a suede leather element (64)is formed completely about the exterior of the heel support (59),including the bottom surface of the ledge (61). The upper edges of theinner liner (63) and the outer suede element (64) are attached, as bystitching, for example, to complete the counter (16). The ledge (61) andelement (64) are adhered to the base of element (28) at the heel areathereof (FIG. 4), having a thickness comparable to that of the vampstrap ends (41), (42), (44) and (46).

It should be noted that the orthotic unit (12) including the heel inset(13), the vamp unit (14) and the counter (16) are assembled together asa composite unit, with that composite unit then adhered with the face(45) of the sole proper (17). The glued ends (41), (42), (44) and (46)(FIG. 4) of the straps (39), (43) are fitted into and glued to therespective recesses (24'), (26'), (24), (26) of the sole proper (17).The ledge (61) of the counter (16) with the exterior element (64) arefitted into and adhered to the rear recess (27) (FIG. 5), furthersupport provided by adhering the lower exterior circular portion of thecounter (16) to the inner face of the raised portion (21) of the soleproper lip (19) (FIG. 3).

I claim:
 1. A footwear construction custom-made for a wearercomprising:a sole having a forward portion and a heel portion; anorthotic unit prescribed specially for a foot of the wearer, and adheredto said sole; a vamp unit secured to said sole adjacent said forwardportion; a counter secured to said heel portion of said sole andprojecting upwardly therefrom; said sole having further an upturned lipformed about the periphery thereof; said sole having further an upperface, and with a plurality of recesses of predetermined spacing formedwithin the said upper surface thereof, and wherein one said recess has aU-shape and is formed about said heel portion; said orthotic unitincluding further a semi-flexible component having an outline similar tothe outline of said sole and placeable onto said sole and within saidlip; said orthotic unit component having an upper face and a lower face,and including further a shock absorbing heel inset secured to saidcomponent upper face, said inset having a U-shaped semi-circularperiphery; and said counter including a rigid cut-shaped element havingan inturned lip, said element secured about the periphery of saidcomponent with said lip secured to said lower face and nested into saidU-shaped recess.
 2. A footwear construction custom-made for a wearercomprising:a sole having a forward portion and a heel portion; anorthotic unit prescribed specially for a foot of the wearer, and adheredto said sole; a vamp unit secured to said sole; and a counter secured tosaid heel portion of said sole and projecting upwardly therefrom; saidvamp unit including a forward vamp portion and a rear vamp portion, saidforward vamp portion including left and right V-shaped strap units, saidleft unit having a pair of legs with outer ends each secured beneathsaid orthotic unit to said sole, and with inner ends joined together andto which joint a fastener is secured, said right unit having a pair oflegs with outer ends each secured beneath said orthotic unit to saidsole, and with inner ends free to each pass through said fastener, saidright unit legs having respective hook and loop fastener portionsaffixed thereto on facing surfaces, said outer ends of each left andright units spaced apart to form openings therebetween; and said vampunit including further a strap secured at one end to one side of saidcounter and an opposite end of said strap operably connected to anopposite side of said counter for extending over the instep of the footof the wearer.